Electrically Conductive Building Blocks With Anti-Symmetric Contact Mechanisms

ABSTRACT

The invention herein discloses a system including building blocks intended for educational, amusement or functional use of assembling into mechanical and electro-mechanical constructions. The building blocks are electrically conductive and have an electrical connector with an asymmetry property around one of the main, or natural, assembly planes. The asymmetric properties allow the connector to maintain high electrical conductance when assembled near an adjacent building block, without harming the building blocks physically and without requiring complex assembly rules and restrictions. The system can present rotational symmetry of 180 degrees, and can present elastic properties or magnetic properties to further increase the conductivity and durability of the connectors.

FIELD OF THE INVENTION

The present invention relates to the field of toys, hobbies, educationalaids and home tools, and more particularly, yet not exclusively relatesto building blocks allowing a user to build models for decorative,educational, amusement, practical or other purposes.

BACKGROUND OF THE INVENTION

Providing building blocks for design and assembly by individuals orgroups has been known for many decades as an activity carrying thepotential to encourage imagination, creativity, technical skills,practical knowledge, group dynamics and stress relief. Out of a varietyof common hobbies and past-time activities, using existing buildingblocks to create a de-novo construction or follow instruction to createsome desired one, has shown to be both useful and enjoyable. While inthe past, such building blocks were generally confined to mechanical orelectro-mechanical disciplines (construction and in some cases electricmotors), market demand and innovation has led to implementation of moresophisticated tools that allow the construction of electrical circuitryand extended functionality, even when performed by hobbyists andnon-specialists. As a result, a need has arisen for the combination ofmechanical building blocks with electrical conductivity, in such a waythat does not hamper the mechanical functionality and the userexperience.

A variety of solutions were shown in the art for the above-stated task,whereas, it will be shown hereafter that all solutions in the art showsome significant limitations. US20110143629 has shown the use ofinterconnectable building blocks with at least some conductive surfacesfor the purpose of building electrically connected circuits. Theconnection, being of a snap-in type along the intuitively verticaldirection is intended for stacking electrically conductive paths ratherthan implementing them in all 3 dimensions (namely sideways in additionto up and down).

Further to this, U.S. Pat. No. 9,914,065B2 has shown a solution toprovide a sideways connection by introducing a spring-like arm allowingfor the pressure exertion between two adjacent blocks, even in such ascenario in which the spring arm is not facing another spring arm, but aregular building block wall. In such a case, the spring arm is fartheraway the desired connection point, and thus the required displacement ishigher and potentially achieved pressure is lower. In the configurationdisclosed in said patent publication, the spring arm exerts a sidewaysas well as an upwards pressure that causes both extended wear-and-tearon the spring itself, other springs, the walls and other components,thus promoting fracture and reducing the building blocks' robustness.Furthermore, the upwards force component causes the stacking andconnection actions to become more difficult and might harm the buildingblocks' functionality and user experience.

Further to above-stated disclosure of patent U.S. Pat. No. 9,914,065B2,it shows the use of designated parts of the building blocks when coveredwith additional materials, referred to as ‘pads’. Said pads areintroduced to allow the pressure from the spring-arms to be securelyconnected to specific, and pre-designated parts of the building blocks,thus allowing the galvanic connection between them. However, not onlydoes the pad introduction incur additional cost, it hampers the use ofthe building blocks, as it limits the design and implementation tospecific directions and configurations. It does not address the need toconnect the building blocks when no pad is present, (spring to wallconnection) or when no spring is present (pad to pad or pad to wall).This solution thus limits both the system's durability as well as itsfunctionality.

U.S. Pat. No. 8,371,894B1 shows a connection mechanism of toy boybuilding blocks intended for use with illumination from the flowingelectrical power. This patent discloses a coupler element based on aplug-and-socket mechanism to connect blocks sideways. While it canprovide a strong coupling mechanism, it limits the usability and incursadditional manufacturing costs due to the mechanism's complex shape.

Patent KR100946794B1 teaches the use a magnetic connection mechanism forlight emitting building blocks by providing a connection force betweenelectrodes on two different blocks. The blocks can be stacked on top ofeach other or sideways and be made in different shapes, but the price ofthe magnetic electrodes is high.

U.S. Pat. No. 10,653,973B2 teaches a plurality of stackable buildingblocks with internal electronics and a socket connection mechanismembedded into the stacking connector. The connector mechanism includingconcentric pin and ring configuration. The connection is only meant forspecific blocks to reach a power supply and not for an entire creativeassembly that allows connection regardless of structure.

Patents US20180145448A1, EP2217341B1 show connectors to securely holdelectrical connection including for data transfer or power supply,whereas the connector in use is provided as a unique connector ratherthan an integrated part of the building blocks. While the connectorsallow the connection of cables or wires to a construction made ofmechanical building blocks, it only provides partial functionality tothe construction as a whole.

There is thus a need to improve the connectivity, durability and theapplicability of building blocks to allow the functional, and enjoyableuse as a creative, educational or hobby utility.

SUMMARY OF THE INVENTION

The present invention shows a plurality of inter-connected buildingblocks with galvanic and mechanical properties that allow the creationof electrical circuitry. Said building blocks, as a stand alonecomponent, or when combined or integrated with additional equipment,component, electrical devices, communication devices and others, form asystem intended for use for amusement, educational, practical or otherpurposes.

To negate the drawbacks of abovementioned art, the current inventionshows a plurality of solutions for the implementation of electricallyconductive building blocks, maintaining the desired properties ofstackable and connectable blocks, while providing with the robust,repeatable and durable galvanic connectivity.

In some embodiments, at least one asymmetric is introduced to the shape,galvanic properties, elastic properties or any combination thereof. Suchan asymmetry typically allows for the connection to fit on both sides ofa building block by preventing overpressure on the physical contactpoint.

In its preferred embodiment, and without any limitation to thegeneralization and scope of the invention, the invention hereindiscloses an asymmetric lateral connection mechanism that allows for theusage of small distances separating the building blocks to serve as avolume for galvanic connection without introducing high pressure thatmight harm the user experience when trying to assemble building blocks,and without the requirement to stack them from a specific side, withadditional materials or to perform an additional action for theconnection to form. The asymmetry is typically introduced around theplane defined by a horizontal line crossing the center of gravity orcenter of volume of the building block when observed from a top view,defined by the direction of stacking of the building blocks one on theother or on a base board.

The introduced asymmetry is schematically visualized for example in FIG.1 , where the sides are covered with protrusions, depressions,indentations, plugs, sockets, slits, apertures or any other shape oradditional component intended to leave a planar wall to create agalvanic connection. The asymmetry thus causes the distance protrudedand indented from the wall plane to the contact point to be lower thanwould have been in a symmetrical configuration. Furthermore, theasymmetry tends to exert forces in a tilted plane with reference toabove described plane, and thus induce structural integrity and preventdetrimental effects to the building blocks themselves or to theconstruction made thereof.

In some embodiments, the building blocks are made to be electricallyconductive by the introduction of a metallic surface coating, metallicconnectors, conductive polymers coating, conductive polymer blockmaterial, metal block material, internal conductive parts such as aninternal conductive core or others.

In some embodiments, the tactile or connectivity properties of thebuilding blocks are enhanced with springs, spring-like arms, elasticmaterials, shapes intended to bend or any other property allowing forthe distance between the intended galvanic contact point to the wallplane to change with pressure or force.

In some embodiments a magnetic component is introduced as a permanentmagnet, ferromagnetic material, paramagnetic material or a conductivecoil, typically causing a spontaneous or a triggered force to connecttwo or more conductive sides.

In some embodiments, a mechanical mechanism is implemented to allow theconnect or disconnect of two or more sides of the conductive parts of abuilding block. Such mechanisms can be rotary (screw and tap), linear,button based or others.

BRIEF DESCRIPTION OF THE FIGURES

The figures attached hereto are representative of some of theembodiments described in the text and are intended for the purpose ofexplanation and clarification for a reader or observer with relevantskills in the art. The figures are intended to illustrate and exemplifyand do not hold the full structural detail described herein.

In the Figures:

FIG. 1 constitutes a schematic top perspective view of a block withreflection asymmetric connections. The block shows a 180 degreesrotational symmetry

FIG. 2 constitutes a schematic top view of two building blocks withreflection asymmetric connections showing the protrusion creating acontact point when opposed to a wall

FIG. 3 constitutes a schematic top view of two building blocks withreflection asymmetric connections showing the protrusion creating acontact point when opposed another protrusion

FIG. 4 constitutes a schematic top perspective view of a block withreflection asymmetric connections from all lateral sides

FIG. 5 constitutes a schematic top view representation of multiplebuilding blocks of different shapes connected together in some arrayexemplifying the construction process

FIG. 6 constitutes a schematic bottom isometric view of potential wallthinning for added flexibility and durability.

FIG. 7 constitutes a schematic top view showing an embodiment withasymmetric protrusions marked against the symmetry plane

FIG. 8 constitutes a schematic cross sectional top isometric viewshowing a close-up presentation of the connection mechanism in FIG. 7

FIG. 9A shows a representation of a common connection mechanism in thestate of the art exerting forces horizontally due to the symmetricstructure

FIG. 9B shows a representation of an asymmetric connection mechanismexerting forces in diagonal directions, tilted in relation to the wallplane

FIG. 10 constitutes a different embodiment of an asymmetric mechanismshowing jagged connectors

FIG. 11 constitutes an isometric view of an embodiment with jaggedconnectors and a slit with a thinner wall for increased flexibility.

FIG. 12 constitutes an isometric view of an embodiment using acombination of slits and hemispherical bumps

FIG. 13 constitutes an isometric view of an embodiment using a flexibleprotrusion.

FIG. 14 shows an electrical measurement of one embodiment in differentconfiguration achieving sufficiently low electrical conductivity forintegrating circuits.

DETAILED DESCRIPTION OF SOME EMBODIMENTS

In the following detailed description, specific details are set forth inorder to provide a thorough understanding of the invention. However, itwill be understood by those skilled in the art that the presentinvention may be practiced without these specific details. In otherinstances, well-known methods, procedures, and components, modules,units and/or circuits have not been described in detail so as not toobscure the invention. Some features that are presented with respect toone embodiment are not repeatedly presented for another. The detaileddescription makes references to the figures where similar numbers referto similar components.

In its preferred embodiment, the invention herein shows the use of atleast one asymmetric property in a building block, typically used as atoy, to allow the galvanic (electrical) connection of adjacent blocksfor such purposes as building electric circuits and electromechanicalsystems with said blocks. The galvanic connection is based in itsessence on two aspects:

-   -   1. The building block, or a part of it is electrically        conductive, thus allows electricity flow when connected in a        circuit;    -   2. Some protrusion from the building block can touch and close        an electric circuit with additional blocks of the same type, of        different types or with wires, electric components or other        components.

The combination of said aspects allows the construction of mechanismswith embedded electronics, motors, illumination, sensors, communicationsor other electrically actuated components.

Building blocks of the stackable and connectable types are typicallystacked in some vertical direction in such a way that the bottom of ablock is firmly secured to another block or a base plate underneath it.Said blocks are typically manufactured with an engineered gap in thelateral directions between them when assembled, in order to prevent theneed of high force exertion during assembly and in order to increasedurability and prolong their life span. Thus, even in case of a fullyconductive building block, in a typical assembly, the air gap betweentwo blocks located adjacently in the lateral direction will prevent ashort-circuit between them and the flow of electricity.

While prior art has shown the use of protrusions, sockets and plugs toconnect such building blocks, the invention herein presents the use of aconnection mechanism with at least one asymmetric aspect around one ofthe axes or planes defining a building block.

In the preferred embodiment, a building block has a rectangular shape inthe top view (projection along stacking direction), defined by 4 walls.The line connecting the centers of each two opposite walls in such aconfiguration defines a symmetry plane when extruded along the bottom totop direction. The invention herein shows the use of an asymmetricconfiguration of protrusions, poles, buttons, bulges, slits, sockets,crevices, apertures, holes or other shapes and elements in a way that istypically set around the above-defined plane. For example, forillustrative purposes only, FIG. 1 shows a protruding and inwardconverging mechanism (101) that forms an electric connection with asufficiently low electric resistance and impedance with such values as0.0001-1 Ohms per a 2-block connection, as FIG. 2 schematically showsthe connection when it is formed between the protrusion of the connectorelement (101) and a standard wall (102) in an adjacent building block.FIG. 3 shows the same schematic building blocks when forming aconnection between the connector protrusion (101) and another connectorprotrusion.

In the preferred embodiment, the building blocks show some asymmetryalong at least one line or plane, that is typically an anti-symmetricreflection in order to allow both the direct fitting to a similarconnector in another building block, as well as to properly fit a planewall of a building block without such a connector. In both cases, theasymmetry prevents the application of overpressure that can cause amisfit of components or an increased wear. It is thus emphasized, yet isonly given as an example that in some embodiments, the asymmetry isaround a central point or line, which can be through a building blockwall's center or the center in at least one projection of said wall.

In some embodiments the electrical resistance of a single blockincluding the connections can be in the range of 0.0001-0.001 as can beseen as a general example in a 4-probe measurement of a 2-blockconnection in FIG. 14 . In other embodiments, the electrical resistancecan be in a different range such as 0.001-1 Ohms, or lower. In otherembodiments, some or all blocks can have semi-conductor properties orallow for super-conductive properties.

In some embodiments, the protrusions, indentations or any otherconnector types are located on some or any of the possible walls. Forexample, FIG. 4 shows a schematic building block of a rectangular shapewith similar connectors on all four lateral sides.

In other embodiments, at least one asymmetry is introduced in theconnector mechanism, around some plane which can be the horizontal planeparallel to the stacking, a plane that is offset from the center of awall, multiple planes with different asymmetries of different types, ortilted planes with reference to the horizontal plane. The asymmetry canbe of an anti-symmetric type, fully asymmetric, include symmetriccomponents, or any combination of said configurations.

Building blocks can take multiple shapes or forms, and while in somepresented embodiments, they are rectangular in shape or can be describedas a set of connected rectangles, in other embodiments, the buildingblocks can take any polygon shape, non-polygon shapes, circular shapes,cone shapes, pyramid shapes or any other protruded 2-dimensional shapeor 3-dimensional shape. The asymmetry can be introduced in any wall orin other cases without a wall and along any arbitrary plane.

The connection point between two connectors, or a connector and anyother side of an adjacent building block can be in the center of thewall plane, as can be seen for example in FIG. 3 or offset from it ascan be seen in FIG. 2 . In typical embodiments, there is at least oneconnection point, that can be a single one, two points, multiple points,a line, a surface, multiple surfaces or any combination thereof.

Some embodiments show jagged connections as are schematically presentedin FIG. 10 and FIG. 11 wherein a plurality of connectors with multiplesurfaces are shown to allow for a galvanic connection with lowresistance and high durability. Such jagged connectors can include aprotrusion (1002), a dent or a hole (1003) and multiple surfaces for theconnections themselves (1001).

In other embodiments, the asymmetry is introduced in different parts ofbuilding blocks with non-conformal shapes that extend beyond a box, asis depicted in FIG. 5 . Shapes can include ‘L’ Shapes with right angles,different polygon shapes, circular or arc based shapes.

In some embodiments, the walls or other parts of the building blocks arethinner than the rest in order to attribute flexibility to the walls toact as elastic components, in conjunction with spring arms, with othermoving components, or in a stand-alone fashion. Such thinning isexemplified in FIG. 6 as component 601, with or without sink,depressions, dents or protrusions (602, 603) to act as part of thethinning, or separately. Wall thinning can be used for added flexibilityfor purposes of increased durability, improved usability or improvedelectrical connectivity.

In some embodiments, the asymmetrical connection is designed to exertforces in the perpendicular direction to the building blocks walls. InFIG. 8 a schematic view of an asymmetrically fitting depression andprotrusions are shown to exert elastic forces in said direction. Theimplication of the assembled blocks' forces is shown in FIG. 9A and FIG.9B, highlighting the advantages of eliminating some of the perpendicularforces and thus increasing the robustness of the system.

In some embodiments, the building blocks include an increase surfacearea intended for conductivity, for the exertion of friction forces orfor any combination thereof. Such embodiments include jagged teeth thatfit one into the other as shown in FIG. 10 wherein components (1002) and(1003) are asymmetrically fitting protrusions and dents, with (1001)showing a set of jagged teeth to increase the available surface area forcontact.

In some embodiments, an elastic part that can be symmetric or asymmetricis introduced with or without the combination of above mentionedembodiments to increase the ability for motion. FIG. 11 shows forexample a symmetric slit introduced for the thinning of at least onepart of the building block wall. Similarly, yet in a differentembodiment, FIG. 12 shows a dual slit configuration which allows bendingof a building block wall with a hemispherical bulge for electricalcontact.

Some embodiments have a rotational symmetry around a natural centralaxis, typically a perpendicular axis to the assembly plane, and an axisthat goes through the center of volume or the center of mass of thebuilding block. However, some embodiments of building blocks do not havethis rotational symmetry. FIG. 13 shows a single sided building blockwith an asymmetric connector and a slit for increased flexibility.

In some embodiments, the building blocks are coated in order to form athin layer of a conductive material around an existing or a manufacturedbuilding block. Said coating can be performed chemically,electrochemically, by depositing in an electrolyte reservoir, by dipcoating, by brushing, spraying, sputtering or any other coating ordepositing method known in the art. The materials introduced for thecoating are typically ones with relatively high electrical conductivitysuch as metals, alloys or composite materials with electricallyconductive properties. Such materials include, yet are not limited to,Cr, Cr(III), Sn, Cu, Ni, Al, Mo, Ag, any alloys thereof and any of saidmetals or others when added to a polymer, polymer mixture, organiccompounds, conductive inks or other composite material.

In some embodiments, the coating is modified to have additional surfaceproperties such as anti-corrosion properties. For such purposes,passivation can be induced to create yet thinner layers on the coatingitself, additional metals or alloys can be introduced, additionalorganic compound can be added or other corrosion resistantmodifications.

In other embodiments the coating is modified to show surface propertiesto improve the functional electrical connection by changing the surfaceroughness. For example, the surface roughness can be reduced to preventmicroscopic protrusions and increase the contact area. Such amodification can be performed by etching, electro-etching, mechanicalpolishing, electro-polishing, sand paper polishing or any other type ofmethod to induce surface smoothness and minimize roughness.Alternatively, the surface roughness can be increased to induce adhesionor control electrical resistance, for example by patterning the surface,corrugating the surface or inducing abrasion over it.

In some embodiments, the connection mechanism is enhanced, or is solelycontrolled by a spring-like element that exerts forces in the outwarddirection, or with a component oriented in the outward direction. Suchspring like elements can be based on the same material of the buildingblock itself and form by a simple extrusion out of it, they can be madeof an additional material such as a plastic, metal, alloy or ceramicaddition. In some embodiments, the additional or protruding component isof a leaflet shape, helical (coil) shape, flat spiral shape, arc shape,cantilever shape or any other shape exerting force under pressure.

In some embodiments, the materials used for the spring arms are suchthat present high elasticity, super elasticity or shape memoryproperties such as Nickel Titanium alloys, shape memory plastics,Silicon Nitride ceramics, and specifically micro-mechanical Si3N4 thatpresents high elasticity.

In other embodiments, magnetic materials or components are used for theconnecting mechanism. For example, a magnetic material that isintroduced to the connection surface can exert forces when present inclose proximity to another connector. In some embodiments a permanentmagnet is introduced as a thin layer to the aforementioned spring arm orto the connection surface. In some embodiments the material in use is astrong permanent magnet such as Neodymium magnets (NdFeB),Aluminum-Nickel magnets (AlNiCo), Samarium magnets (SmCo), Ferritemagnets, a composite material with magnetic properties or any othermaterial with permanent magnetic properties. In other embodiments,electromagnets or ferromagnetic materials are used separately or incombination with each other to cause the same attraction effect betweentwo sides of a connector. In some embodiments, the electric currentthrough the building blocks is used to energize electromagneticproperties of coils to increase the attraction between two sides of theconnecting points.

In some embodiments, magnetic materials are used as described above, inconjunction to mechanical elements allowing for the motion, translationor rotation of one magnet in reference to the other in an adjacentbuilding block in order to allow the alignment of opposing poles one infront of the other to exert a higher force between them. As anillustrative example, the magnet can be a single cylinder withdiametrical magnetization orientation and two poles on each side of thebuilding block in an anti-symmetric fashion.

In some embodiments, a permanent magnet is added as a thin layer by someprocess such as electrodeposition, sputtering, dip coating or other inorder to use a small amount of material while allowing for attractiveforces between two opposing sides of the connection point betweenbuilding blocks when in close proximity.

In some embodiments, additional mechanical components are used toincrease the pressure or force exerted between adjacent building blocks.Such mechanisms can include, yet are not limited to, buttons, screws,taps, cantilevers, pins, protrusions, holes or others. Such connectionassisting mechanisms can trigger a connection at a user action such aspressing or rotation, or can increase the connectivity further bylowering the electrical resistance. Conversely, such mechanisms can beapplied in some embodiments to disconnect the building blocks from theiradjacent ones.

In some embodiments, an internal mechanism galvanically connects two ormore sides of the building block. Such internal mechanism can be a rod,a strip, a wire or any other internally confined component, typicallymade of a metal, an alloy or a composite material presenting highconductivity. Said internal components can be used as a stand-alongmechanism or in conjunction with above-mentioned thin conductive coatingin order to decrease the total resistance of the building block.

The invention herein can typically work in conjunction with powersupplies such as direct current or alternating current power supplies,batteries of different types, generators, wires and connectors. In someembodiments safety and switching mechanisms are implemented such as,switches, fuses circuit breakers, reed switches, arc fault protection,over-temperature protection, over-current protection, ground faultprotection or any other type.

In some embodiments, the invention herein is used in conjunction withexternal electronics for monitoring, metering or controlling electricityuse, function use or other. In some embodiments, one or more componentis connected to external control units such as microprocessors,computers, mobile phones or others through some communications protocolsuch as Internet protocol, Bluetooth, NFC, Wifi, Zigbee or other digitalor analog communications.

1. A system comprising of building blocks intended for use in hobby, amusement, educational or functional construction that present electrically conductive properties to allow integration of electronic, power or electromechanical circuits into the construction, wherein the connection mechanism between adjacent building blocks has at least one asymmetry along an axis or a plane, and does not have a symmetrical reflection property around at least one central plane.
 2. The system in claim 1 where the asymmetry is along a plane perpendicular to the natural assembly direction.
 3. The system in claim 2 where the asymmetry is anti-symmetric reflection.
 4. The system in claim 1 where the building block shows a rotational symmetry around one of its natural central lines such as the line perpendicular to the natural assembly plane.
 5. The system in claim 1 where the asymmetry is along a plane parallel to the natural assembly direction.
 6. The system in claim 1 where at least one asymmetrical feature is defined around a plane that is not defined
 7. The system in claim 1 where the building blocks are coated with a metal, an alloy, a conductive polymer or another electrically conductive material.
 8. The system in claim 1 where the building blocks are made at least in part of an electrically conductive material.
 9. The system in claim 1 where a magnetic component is introduced to exert forces for increased electrical connectivity.
 10. The system in claim 9 where the magnetic component is coated, sputtered or deposited in a thin layer.
 11. The system in claim 1 where the building blocks have at least one elastic component to serve as a spring.
 12. The system in claim 11 where the elastic component is a spring arm in the shape of a leaflet spring.
 13. The system in claim 11 where the spring element is made of a super-elastic material.
 14. The system in claim 1 where the connectors use jagged teeth.
 15. The system in claim 1 where the connectors are designed to be thinner for increased flexibility. 